Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Operator's Manual
MOBILE ACCESS PLATFORM
TYPE Alulift
(Translation)
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Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
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Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Table of Contents
1. GENERAL INFORMATION ............................................................................................................................. 6
1.1. Manufacturer ................................................................................................................................................... 6
1.2. Machinery Marking ....................................................................................................................................... 6
1.3. Definitions ........................................................................................................................................................ 7
1.4. Safety symbols used in this Manual ......................................................................................................... 7
1.5. National requirements ................................................................................................................................. 8
1.6. Declaration of Conformity .......................................................................................................................... 9
2. TECHNICAL DATA ........................................................................................................................................ 10
2.1. Use of PRP type Alulift for its intended purpose.............................................................................. 10
2.2. Failure to use PRP type Alulift for the intended purpose ............................................................. 10
3. DESCRIPTION OF THE PRP CONSTRUCTION AND OPERATION AND ADJUSTMENT OF
SAFETY COMPONENTS ............................................................................................................................... 11
3.2. List of Components Necessary for PRP type Alulift Assembly .................................................... 14
4. DESCRIPTION OF THE DRIVE SYSTEM CONSTRUCTION, OPERATION AND ADJUSTMENT 16
4.1 Drive Unit ....................................................................................................................................................... 16
4.2 Service brake ................................................................................................................................................ 16
4.3 Emergency Brake - Emergency Gripper .............................................................................................. 16
4.4 Control Pendant ........................................................................................................................................... 16
4.5 Audio Alarms. ............................................................................................................................................... 17
4.6 Wheel Brakes ................................................................................................................................................ 17
4.7 Safety system to prevent platform overloading ............................................................................... 17
4.8 Drive operating time meter ..................................................................................................................... 17
4.9 Battery charger ............................................................................................................................................ 17
5. ASSEMBLY AND DISASSEMBLY INSTRUCTIONS ................................................................................ 18
5.1. Assembly ........................................................................................................................................................ 19
5.2. Conditions of stability - variants of stabilizers ................................................................................. 26
5.3. PRP type Alulift S anchoring instruction ........................................................................................... 28
5.4. Disassembly .................................................................................................................................................. 29
5.5. Battery Disassembly .................................................................................................................................. 30
6. OPERATOR'S MANUAL ............................................................................................................................... 30
6.1. Control via control pendant ..................................................................................................................... 31
6.2. Operator's working station ...................................................................................................................... 31
6.3. Operator's qualifications .......................................................................................................................... 31
6.4. Handling PRP ................................................................................................................................................ 32
6.5. Troubleshooting .......................................................................................................................................... 32
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7. HAZARDS IDENTIFICATION AND RESIDUAL RISK INFORMATION ............................................. 34
8. SAFETY GUIDELINES. .................................................................................................................................. 35
8.1. Lighting ........................................................................................................................................................... 36
9. MAINTENANCE INSTRUCTIONS .............................................................................................................. 36
9.1. Maintenance Operator .............................................................................................................................. 36
9.2. Maintenance and Inspection Schedule ................................................................................................ 36
9.3. Pre-assembly reviews ............................................................................................................................... 37
9.4. Maintenance Reviews. ............................................................................................................................... 37
9.5. Ad hoc and Service Reviews. .................................................................................................................. 38
10. CRITERIA FOR COMPONENTS REPLACEMENT .................................................................................. 38
11. STORAGE AND TRANSPORT ..................................................................................................................... 38
12. AN INFORMATION BOARD PLACED ON THE PRODUCT ................................................................. 39
13. Guarantee and warranty .......................................................................................................................... 40
14. APPENDIX No. 1………………………………………………………………….………………………….......…………..42
15. APPENDIX No. 2……………………………………………………………………………………………………..………..43
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Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
LOCKHARD is not liable for any damage resulting from failure to
comply with this Manual.
Any risk in this respect shall be borne by the user.
Foreword
We would like to inform you that the Mobile Access Platform type Alulift has passed a detailed EC
type examination carried out by the certification body JOAiCW TEST Sp. z o.o. [Ltd] .
The confirmation of the positive result of the inspection carried out by JOAiCW TEST Sp. z o.o. is the
Type Examination Certificate issued.
Lockhard Sp. z o.o. [Ltd] is the only manufacturer of the Mobile Access Platform (Polish: PRP) type
Alulift with a mobile work platform.
This Operator's Manual is considered to be a fundamental part of the Mobile Access Platform type
Alulift. It contains all the necessary information on the assembly, disassembly and operation of the
device as well as users' work safety and the information on how to maintain its efficiency.
A full and legible user's manual must be accessible at all times. "Mobile Access Platform type Alulift"
will be hereinafter abbreviated as "PRP".
In order to avoid unnecessary damage and risks, the operator's and the assembly worker's
responsibility is to read, understand and comply with this Operator's Manual.
In addition to this PRP Operator's Manual, general legal provisions and regulations concerning
accident prevention and environmental protection in force in the user's country shall apply.
You should refer to all the national and local rules for operating PRP type Alulift on site.
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Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Lockhard Sp. z o.o.
Gorzyce Wielkie ul.Ostrowska 74a
63-410 Ostrów Wielkopolski
POLSKA
Product:
Mobile Access Platform type Alulift S
Alulift Type: S
Weight: 48.3 kg – 330 kg
Safe working load: 250 kg
Voltage: 24V DC
Platform dimensions:
660x1720mm
Engine power: 600 W
Lift height: 8 m
Serial number: xxx
Platform speed:10 m/min
Year of manufacture: 2015
Lockhard Sp. z o.o.
Gorzyce Wielkie ul.Ostrowska 74a
63-410 Ostrów Wielkopolski
POLSKA
Product:
Mobile Access Platform type Alulift M
Alulift Type: M
Weight: 55 kg – 475 kg
Safe working load: 250 kg
Voltage: 24V DC
Platform dimensions: 660x2400mm
Engine power: 600 W
Lift height: 12 m
Serial number: xxx
Platform speed: 10 m/min
Year of manufacture: 2015
Lockhard Sp. z o.o.
Gorzyce Wielkie ul.Ostrowska 74a
63-410 Ostrów Wielkopolski
POLSKA
Product:
Mobile Access Platform type Alulift XL
Alulift Type: XL
Weight: 67 kg – 524 kg
Safe working load: 250 kg
Voltage: 24V DC
Platform dimensions:
1100x2400mm
Engine power: 600 W
Lift height: 12 m
Serial number: xxx
Platform speed: 10 m/min
Year of manufacture: 2015
1. GENERAL INFORMATION
1.1. Manufacturer
LOCKHARD Sp. z o.o.
Gorzyce Wielkie ul. Ostrowska 74a
63-410 Ostrów Wielkopolski
e-mail: office@lockhard.eu
www.lockhard.eu
1.2. Machinery Marking
Alulift S
Alulift M
Alulift XL
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1.3. Definitions
Mobile Access Platform (PRP) - is a mobile machine intended to move persons to working
positions on which they carry out work from the work platform, on the assumption that these
persons enter the platform and exit the platform in its one lower access position, and which
consists of the work platform with controls, a load-bearing structure, a wheel assembly.
Work platform - a part of the mobile platform, a platform with railings, which can be moved
under load to a desired working position, and from which you can perform installations, repairs,
inspections or similar works.
Operator - a designated person, suitably trained to operate devices of this type subject to laws
and regulations applicable in a particular country. In Poland an operator must have proper
qualifications awarded by the Office of Technical Inspection (an operator may also work as a
service technician).
Service technician is a person who has been sufficiently trained by the manufacturer of the
device type Alulift, namely Lockhard Sp. z o.o. Each periodic replacement of parts or ad hoc
repairs of the device may be carried out by the manufacturer's service technicians or service
units authorized by the manufacturer.
Safe working load - the maximum weight carried by the work platform provided for by the
manufacturer in the design/specifications of the device. The safe working load comprises the
weight of persons, tools and materials placed on the platform.
1.4. Safety symbols used in this Manual
In order to draw your attention to the areas in this Manual which contain important information or
indicate danger, the following symbols are used. Special attention should be paid to areas marked
with these symbols as you study the instructions for use.
Danger
This symbol indicates an immediate threat to person's life and health.
Failure to comply may result in a risk to life or a risk of serious injury and a
significant property damage.
Caution
It is a warning against possible damage to PRP or another item, if the action
marked in this way is performed incorrectly.
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1.5. National requirements
In addition to this Operator's Manual, attention should be given to the need to know and comply
with the generally applicable national and local laws and other binding regulations relating to work
safety and environmental protection in the country where the machine is used.
In the Republic of Poland "Mobile Access Platform type Alulift" serving as a device for the movement
of persons and loads is a device qualifying for handling equipment and is subject to technical
supervision. It is the user's responsibility to report the equipment to UDT [Polish Office of Technical
Inspection].
Legal basis:
Regulation of the Council of Ministers of 7 December 2012 on types of technical devices subject to
technical inspection (Official Journal of Laws 2012 No. 0, item 1468), issued pursuant to Article 5,
paragraph 2 of the Law on technical inspection.
Pursuant to the Regulation of the Minister of Economy, Labour and Social Policy of 29 October 2003
on the technical conditions of technical supervision relating to operating certain types of handling
equipment. Pursuant to art. 25.1 item, 6 after changing the location of handling equipment due to
its disassembly and reassembly, a device with single-phase power supply does not require interim
in-service testing.
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Technical Manager:
Łukasz Leonhard
1.6. Declaration of Conformity
EC DECLARATION OF CONFORMITY
Manufacturer: LOCKHARD Sp. z o.o.
Gorzyce Wielkie ul. Ostrowska 74a
63-410 Ostrów Wielkopolski
Product: Mobile Access Platform type Alulift
Serial number: ……………………….
We declare under our sole responsibility that the product referred to above fulfils the essential
health and safety requirements of the Directive 2006/42/EC OF THE EUROPEAN PARLIAMENT AND
OF THE COUNCIL.
The EC type examination was carried out by the notified body JOAiCW Test Sp. z o. o., number
NB2057, 41-103 Siemianowice Śl. ul. Wyzwolenia 14, which issued the CE Type Examination
Certificate No. ………………………….
The Product carries the mark:
The technical documentation is stored at:
Gorzyce Wielkie, dated ……………
LOCKHARD Sp. z o.o.
Gorzyce Wielkie ul. Ostrowska 74a
63-410 Ostrów Wielkopolski
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Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
ALULIFT S
ALULIFT M
ALULIFT XL
Safe working load
250 kg (2 persons,
tools and materials)
250 kg (2 persons,
tools and materials)
250 kg (2 persons,
tools and materials)
Work platform dimensions
660x1720 mm
1100x2400 mm
1100x2400 mm
Maximum platform lifting
and lowering speed
10 m/min (at full
battery power)
10 m/min (at full
battery power)
10 m/min (at full
battery power)
Maximum height
approx. 330 kg
approx. 475 kg
approx. 530 kg
Maximum PRP weight
8m- internal height
12 - external height
8 m – internal height
12 - external height
8 m – internal height
12 - external height
Supplied voltage
VDC 24
VDC 24
VDC 24
Engine power
600 W
600 W
600 W
Maximum drive motor speed
3000 rpm.
3000 rpm.
3000 rpm.
Transmission ratio
1:100
1:100
1:100
Battery capacity
33 Ah
33 Ah
33 Ah
Battery voltage
2x12 V
2x12 V
2x12 V
Operating temperature
-15° C up to +40 ° C
-15° C up to +40 ° C
-15° C up to +40 ° C
Noise
does not exceed 70dB
adjusted individually
does not exceed 70dB
adjusted individually
does not exceed 70dB
adjusted individually
2. TECHNICAL DATA
2.1. Use of PRP type Alulift for its intended purpose
"Mobile Access Platform type Alulift" is a mobile machine intended to move persons to working
positions on which they carry out work from the work platform, on the assumption that these
persons enter the platform and exit the platform in its one lower access position. "Mobile Access
Platform type Alulift” consists of the work platform with controls, a load-bearing structure and a
wheel assembly. "Mobile Access Platform type Alulift " can be used indoors and outdoors.
2.2. Failure to use PRP type Alulift for the intended purpose
It is prohibited to use the PRP as a crane.
It is prohibited to apply a point load - the load must be equally distributed across the
platform. Applying a high load on a small area (a point load) may damage the platform.
It is prohibited to use and move the PRP when wind speed exceeds (12m/s - 6 on the
Beaufort scale).
It is prohibited to use the PRP during a storm.
It is prohibited to move the PRP using any motor vehicles such as a car, forklift truck, tractor,
etc.
It is prohibited to use lifting devices (hand or mechanical winches) on the PRP.
Do not increase (obscure) the side surface of the PRP. Increasing the area exposed
to the wind will decrease machine stability.
It is prohibited to stand on the handrails, braces and stabilizers.
It is prohibited to tie rods (excluding anchors) between the PRP and another structure
(buildings, another scaffolding, etc.).
It is prohibited to lean any objects against the PRP structure during assembly and operation.
Not more than 2 persons may stay on the PRP work platform.
It is prohibited to use the PRP that is not properly maintained and inspected or is not in
good technical condition.
It is prohibited to use the device without pin bolts securing structure frames.
It is prohibited to use this device in explosive atmospheres.
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Item
No.
Component
marking
Component photo
Component
description
Weight [kg]
S M XL
1.
PS
Work platform
with a drive
system
48,3
55
67
2.
H264
Horizontal
handrail
5 6 6
3.
HO 264
Handrail with
access gate
6,1
8.5
8.5
4.
TB264
Toe-boards
2,67
6.1
6.1
5.
H95
Side handrail
3.9
3.9
6,9
3. DESCRIPTION OF THE PRP CONSTRUCTION AND OPERATION AND ADJUSTMENT OF
SAFETY COMPONENTS
List of the "Mobile Access Platform type Alulift" components
Each PRP component is marked with a catalogue number in order to identify the PRP system.
Table 1
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6.
FR139100
FG139100
Base frame (right
and left marked
with colours)
supplied with pin
bolts.
Running profile
mounted on the
base frame
10.6
10.6
12,10
7.
DB264
Diagonal braces
2,27
2.85
2.7
8.
HB264
Horizontal braces
2.18
2.70
2.7
9.
CC05
Control pendant
PKS-3/W05
0.5
0.5
0.5
10.
WHEEL125
Small wheel
61125 CB
1.2
1.2
1.2
11.
WHEEL200
Large wheel
61200 CB
5.3
5.3
5.5
12.
BAT33
Gel batteries
Bt-02-12
2x9,5
2x9,5
2x10,5
13.
TE04-0227
Battery charger
TE04-0227
0.8
0.45
0.8
14.
STAB3000
Stabilizer
4.28
4.28
4.28
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15.
RA15
Gear rack
9,8
9,8
9,8
16.
SPR20
Gear
0,68
0,68
0,68
17.
GRA25
Gripper
(emergency
brake)
1,17
1,17
1,17
18.
BFK457
Service brake
BFK 457
19.
AN450
Anchor bolt
2 2 2
20.
LI10-60
Pin bolt
0,05
0,05
0,05
21.
OB
Weight - ballast
10
10
10
Safety guardrails are an integral part of the platform
Pin bolts are an integral part of the load-bearing structure
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PRP height
2m
3m
4m
5m
6m
7m
8m
Component name
Number of components (pcs)
Red structure frame
2 3 4 5 6 7 8
Green structure frame
2 3 4 5 6 7 8
Diagonal braces
4 6 8
10
12
14
16
Horizontal braces
2 2 2 2 2 2 2
Horizontal handrail
1 1 1 1 1 1 1
Handrail with access gate
1 1 1 1 1 1 1
Side handrail
2 2 2 2 2 2 2
Toe-board
3 3 3 3 3 3 3
Stabilizer
- - 4 4 4 4 4
Small wheel
8 8 8 8 8 8 8
Large wheel
4 4 4 4 4 4 4
Battery
2 2 2 2 2 2 2
Platform
1 1 1 1 1 1 1
Total weight in kg
159
185
227
253
279
305
330
PRP height
2m
3m
4m
5m
6m
7m
8m
9m
10m
11m
12m
Component name
Number of components (pcs)
Red structure frame
2 3 4 5 6 7 8
9
10
11
12
Green structure frame
2 3 4 5 6 7 8
9
10
11
12
Diagonal braces
4 6 8
10
12
14
16
18
20
22
24
Horizontal braces
2 2 2 2 2 2 2
2 2 2
2
Horizontal handrail
1 1 1 1 1 1 1
1 1 1 1 Handrail with access gate
1 1 1 1 1 1 1
1 1 1
1
Side handrail
2 2 2 2 2 2 2
2 2 2
2
Toe-board
3 3 3 3 3 3 3
3 3 3
3
Stabilizer
- - 4 4 4 4 4
4 4 4
4
Small wheel
4 4 4 4 4 4 4
4 4 4
4
Large wheel
4 4 4 4 4 4 4
4 4 4
4
Battery
2 2 2 2 2 2 2
2 2 2 2 Platform
1 1 1 1 1 1 1
1 1 1
1
Total weight in kg
192
218
262
292
315
342
368
395
420
448
475
PRP height
2 m 3 m 4 m 5
m 6 m 7 m 8 m
9 m 10m
11m
12m
Component name
Number of components (pcs)
Red structure frame
2 3 4 5 6 7 8
9
10
11
12
Green structure frame
2 3 4 5 6 7 8
9
10
11
12
Diagonal braces
4 6 8
10
12
14
16
18
20
22
24
Horizontal braces
2 2 2 2 2 2 2
2 2 2
2
Horizontal handrail
1 1 1 1 1 1 1
1 1 1
1
Handrail with access gate
1 1 1 1 1 1 1
1 1 1
1
Side handrail
2 2 2 2 2 2 2
2 2 2
2
Toe-board
3 3 3 3 3 3 3
3 3 3
3
Stabilizer
- - 4 4 4 4 4
4 4 4 4 Small wheel
4 4 4 4 4 4 4
4 4 4
4
Large wheel
4 4 4 4 4 4 4
4 4 4
4
Battery
2 2 2 2 2 2 2
2 2 2
2
Platform
1 1 1 1 1 1 1
1 1 1
1
Total weight in kg
211
240
287
316
346
376
405
435
464
495
524
3.2. List of Components Necessary for PRP type Alulift Assembly Table 2
Alulift S
Alulift M
Alulift XL
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Drawing 1 Main PRP components
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4. DESCRIPTION OF THE DRIVE SYSTEM CONSTRUCTION, OPERATION AND ADJUSTMENT
4.1 Drive Unit
The drive system in the PRP type Alulift is an electric motor with 24 V, 600 W and 3000 rpm
speed. It is permanently attached to the CM063 type worm gear of 1 to 100 ratio. The worm
gear output rotational speed is 30 rpm. Actuating force is 114 Nm. A drive shaft φ 25 is
mounted on the worm gear, by which the device driving force is transferred to two extreme
ends of the shaft, where gears are mounted. The gears are splined to the gear rack located in the
vertical structure of the device. Upon starting the drive, the drive shaft is moved by the worm
gear. The rotary motion of the shaft makes the gear rotate, which enables vertical movement of
the platform.
4.2 Service brake
The service brake system is composed of:
The INTORQ BFK457-08 COMPAKT type brake of rated voltage 24V, rated power 25 watt
and nominal braking torque 12 Nm.
CM 050 transmission of 1 to 10 ratio
The service brake has nominal braking torque of 120 Nm, which is sufficient to brake and
maintain a work platform with safe working load of 250 kg. The service brake is an
electromagnetic brake which automatically starts the braking process at the time of control
circuit interruption - power supply loss.
The braking process is carried out using springs pressing the brake pads on the discs. Brake
release occurs at the time voltage is supplied to the solenoid coil.
4.3 Emergency Brake - Emergency Gripper
The emergency brake is made up of two independent grippers which make the platform stop if
the lowering speed exceeds 0.5 m/s. The emergency gripper is triggered by centrifugal switches
forming an integral part of the gripper.
If the gripper and the emergency brake are triggered on the platform, it is necessary to replace the
emergency brake system, which gets damaged during the platform stop (the emergency gripper is
a single-use device) which does not allow its further operation; in this case you should notify the
manufacturer or an authorized service point to have the grippers replaced.
Note - the gripper can be right-side and left-side.
4.4 Control Pendant
Mobile Access Platform type Alulift is able to move vertically up and down. In order to start the
drive which makes the platform move, the control pendant is used. There are three control buttons
on the control pendant. The emergency stop button is a master control button that is used to
disconnect control in the other two buttons. This button has a built-in control system of
continuous disconnection through key locking. The other two buttons located on the control
pendant are used to make the mobile platform move vertically UP and DOWN. These buttons are
marked by arrows and arranged by logical operation on the control pendant.
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Photo 1: Control pendant
4.5 Audio Alarms.
The advance signal - before starting the platform a 5-second audio alarm is triggered
indicating that the platform is going to be started.
The operation signal - emitted while the platform is moving, which warns of possible
trapping, drawing-in or crushing.
4.6 Wheel Brakes
Wheel brakes are mechanical devices preventing the PRP from uncontrolled movement
during operation or stopping.
4.7 Safety system to prevent platform overloading
The PRP is equipped with a safety devices to protect the drive from overloading due to
platform overloading or blocking during upward movement. The overload protector
protects the drive motor during upward movement, and the redundant protector protects
the circuit current of the drive motor and brake. In the event that the safety system is
activated to prevent platform overloading, move downward, reduce the platform load and
wait 90 sec. until the system makes it possible to move upward.
4.8 Drive operating time meter
The drive operating time meter is located under the platform. The drive operating time
meter records and indicates the number of the PRP drive operating hours. In order to ensure
proper meter functioning you should check its status from time to time (preferably it should
be checked before and after operation).
4.9 Battery charger
The PRP drive is supplied with a set of two batteries. A special device is provided for
charging the PRP drive gel batteries.
To connect the battery to the charger, connect the plug of the charger to the distribution
board A. See the photograph below.
To charge emergency system batteries (see item 6.5.2) connect the plug of the charger to
the distribution board B. See the photograph below.
Photo 2 Distribution boards
A- The main distribution board
B- Emergency lowering device
distribution board
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5. ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
Below is the description of the procedure for assembling and disassembling the "Mobile Access
Platform type Alulift " produced by Lockhard Sp. z o.o.
Assembly, disassembly, operation and maintenance of the PRP may only be performed by properly
trained personnel, who must read and fully understand the following procedures and descriptions
before attempting to assemble or disassemble.
Two persons are required for assembly and disassembly. The area of the PRP assembly and
operation must be protected against unauthorized access by third parties.
Pre-assembly works
Before you begin the PRP assembly, check all the elements and components listed in
Table No. 2, which are necessary for its proper operation,
For assembly, use only undamaged and original manufacturer's parts.
Before commencing the PRP type Alulift assembly, check the surrounding area for safety, e.g. if there
are no electrical installations, ruins, rubble, excavations, mobile cranes, pedestrian traffic, any
vehicle or machine traffic, etc. in the area.
If there is a risk of coming into contact with overhead electrical power lines, these lines should be
shut off.
Electrical power lines which are in the distance of the level of free-swinging extreme cables from the
furthest possible outer edge of the transferred elements at the time of PRP operation, assembly and
disassembly do not require being shut off, with the said distance being not closer than:
2 m for a low voltage line of 400V
5 m for a line of up to 15 kV
10 m for a line of up to 30 kV
15 m for a line of over 30 kV
You should check the ground on which PRP will be installed. The ground must be horizontal and
hardened.
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5.1. Assembly
The structure of the PRP provides for quick assembly without the use of tools.
Stage I - platform assembly
The PRP platform should be placed on the destination assembly location.
Photo 3
First, you must install the required side guardrails on the platform.
Photo 4 Photo 5
Connect side handrails to the horizontal handrail and build the handrail with access gate
Photo 6 Photo 7
Install toe-boards
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Photo 8
Remove the covers protecting the gears and the roller guides of the drive system
Photo 9 Photo 10
Stage II - Load-bearing structure assembly
Put the frames of the load-bearing structure with the roller guides on the appropriate sides of
the mobile platform, in accordance with the markings - colour-coded green and red,
Photo 11 Photo 12
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Photo 13 Photo 14
Photo 15 Photo 16
Using the key unlock the emergency stop button on the control pendant. Before pressing the
control pendant buttons, make sure that it is held securely.
Press and hold the white button on the control pendant until the platform is lifted 2 - 10 cm
upwards
PRP Alulift will work properly as long as the gears and the gear racks
simultaneously engage on both sides of the load-bearing structure!
Install two (shorter) horizontal braces connecting PRP base frames
Photo 17
Install diagonal braces connecting PRP base frames on the opposite side of the access gate.
Install one end of the brace on the lowest level of the first segment of the base frame. Install the
other end of the brace on the highest level of the opposite side of the first segment.
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Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Photo 18
The brace hooks should be fitted in the designated places!
Photo 19 Correct position of fitting braces.
Level the equipment using aligning bolts in the wheels and lock the wheels using a brake at each
of the four wheels and check the levelness of the platform using a bubble level. If necessary, the
platform should be levelled by means of adjusting nuts.
Photo 20 the brake left in the locked position Photo 21 the brake left in the unlocked position
Stage III - Further structure levels assembly
From the ground fit further matching frames of the PRP load-bearing structure. (please pay
attention to the colour marking scheme of the components - red and green)
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Photo 22 Photo 23
View of the base frames and mobile platform marking.
Each time after connecting base frames of the structure, secure them by
pin bolts in order to prevent their unintended retracting.
Photo 24 Photo 25
Insert pin bolts in the holes in the pillars of the frame structure. Install diagonal braces
connecting PRP base frames.
Diagonal braces installation
The first brace
Install one end of the brace on the lowest level of the base frame. Install the other end of the
brace on the highest level of the opposite side.
The second brace
Install one end of the brace on the highest level of the base frame. Install the other end of the
brace on the lowest level of the opposite side.
Diagonal braces should be installed in such a way that two grippers of the braces should not be
located on the same level.
The correct braces assembly is shown in the photograph No. 26.
When building the next level, the following should be loaded on the platform:
The red-marked base frame
The green-marked base frame
Two diagonal braces
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While the PRP platform is moving, it is important to remember that all of the
transported components must not protrude beyond the outline of the platform
railings.
Operation may start only if the platform handrails are properly locked to prevent accidental fall.
Move the platform to the most suitable place in order to be able to install the third segment.
Photo 26
Install further frames of the load-bearing structure by matching them according to the colour
marking scheme.
Photo 27
Install diagonal braces connecting PRP base frames. Install one end of the brace on the lowest level
of the third segment of the base frame. Install the other end of the brace on the highest level of
the opposite side of the third segment.
Photo 28
Before commencing the fourth level assembly, four stabilisers should be fitted by screwing them
with radial grips down to the base frame of the structure.
After fitting the stabilizers, check if the stabilizer bars rigidly adjoin the ground in order to make
sure that they are fitted correctly.
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When applying large force, the stabilizer should not move in lateral direction - rotation and in
vertical direction.
Photo 29 Photo 30
After fitting the stabilizers, you can proceed to install the fifth and any further level, according to
the instructions referring to Stage III.
Photo 31
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Alulift S
Alulift M
Alulift XL
Indoors
up to 8 m in height
up to 12 m in height
up to 12 m in height
Outdoors
up to 8 m in height
up to 8 m in height
up to 8 m in height
Alulift S
Alulift M
Alulift XL
Indoors
up to 4 m in height
up to 8 m in height
up to 8 m in height
Outdoors
up to 4 m in height
up to 8 m in height
up to 8 m in height
Alulift S
Alulift M
Alulift XL
Outdoors
up to 4 m in height
up to 8 m in height
up to 12 m in height
5.2. Conditions of stability - variants of stabilizers
Variants of using PRP type Alulift - CONFIGURATIONS
a. With four stabilizers (to maintain stability use weights, according to Table 3)
Drawing 2
b. With two stabilizers placed at elevation of a building (to maintain stability use
weights, according to Table 3)
Drawing 3
c. Without stabilizers:
Drawing 4
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Option
PRP height
4 m
5 m
6m
7m
8m
9m
10m
11m
12m
Load [kg]
Mobile Access
Platform positioned
outdoors with two
stabilizers mounted
on one side
20
20
40
40
60
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
outdoors with four
stabilizers mounted
symmetrically
0
0
0
0
0
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
indoors with two
stabilizers mounted
on one side
20
20
20
40
40
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
indoors with four
stabilizers mounted
symmetrically
0
0
0
0
0
UNACCEPTABLE POSITIONING
Conditions of maintaining stability - variants of load distribution
The load must be evenly distributed!!!
If you use the Mobile Access Platform (PRP) with two stabilizers mounted on one side of the
platform, the weights must be distributed evenly on each stabilizer.
If you use the Mobile Access Platform (PRP) with four stabilizers mounted symmetrically, the
weights must be distributed evenly on each of the four stabilizers.
Photo 32 shows how the weights should be properly distributed on each stabilizer .
Photo 32 Drawing 6
Table 3 Even distribution of load on Alulift
Alulift S
August 2015 Page 27
Alulift M
Option
PRP height
4 m
5 m
6m
7m
8m
9m
10m
11m
12m
Load [kg]
Mobile Access
Platform positioned
outdoors with two
stabilizers mounted
on one side
20
20
40
40
60
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
outdoors with four
stabilizers mounted
symmetrically
0
0
0
0
0
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
indoors with two
stabilizers mounted
on one side
20
20
20
40
40
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
indoors with four
stabilizers mounted
symmetrically
0
0
0
0
0
0
20
20
40
Option
PRP height
4 m
5 m
6m
7m
8m
9m
10m
11m
12m
Load [kg]
Mobile Access
Platform positioned
outdoors with two
stabilizers mounted
on one side
20
20
40
40
60
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
outdoors with four
stabilizers mounted
symmetrically
0
0
0
0
0
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
indoors with two
stabilizers mounted
on one side
20
20
20
40
40
UNACCEPTABLE POSITIONING
Mobile Access
Platform positioned
indoors with four
stabilizers mounted
symmetrically
0
0
0
0
0
0
20
20
40
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Alulift XL
5.3. PRP type Alulift anchoring instruction
The PRP type Alulift platform can be used as an outside elevating platform of up to 8 m. In the
event of such use, the PRP load-bearing structure should be anchored to the wall of a structure
or building in a way as to ensure stability and rigidity of the PRP structure and enable
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PRP height
Number of anchors
Anchoring on frame number
1 m
0
0
2 m
0
0
3 m
0
0
4 m
2
4
5 m
2
4
6 m
2
4
7 m
2
4
8 m 4 4 and 8
9 m 4 4 and 8
10 m 4 4 and 8
11 m 4 4 and 8
12 m 6 4, 8 and 12
transferring external forces acting on the PRP. PRP anchoring must be carried out on an ongoing
basis while erecting the structure. Anchoring fasteners are used for anchoring the PRP. The
fasteners hooks should be combined with screw-eye bolts driven in the wall plugs embedded in
the wall.
Anchoring should start at the height of 4 m.
Anchoring bolts should be attached to the frame one anchor per side and placed symmetrically
on the entire surface. The distance between anchors in the vertical direction should not exceed 4
m. The distance between the PRP and the wall should be suitable to the nature of work in a way
that allows you to safely perform it on the work platform. The anchors should be parallel in
relation to the frames on the outside of the structure during bolting special attention must be
paid so that the anchor bolt would not fall within the outline of the mobile work platform.
Drawing 5 An anchor installed at the platform - Reference drawing
Table 4 Distribution of the anchors
It is prohibited to apply PRP anchoring to gutters, lightning conductors or
window frames.
5.4. Disassembly
In order to start the disassembly, lift the platform to the height of the penultimate
segment of the base frame.
Remove the two diagonal braces connecting the PRP base frames from the highest level
You can only remove the braces from the last segment to be disassembled
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Before the disassembly of the load-bearing structure frames, remove the pins securing
connections between each frame.
Disassemble the load-bearing structure frames.
Before going down, make sure that none of the disassembled components protrudes
beyond the platform.
Take the disassembled components down to the ground level and unload them.
Likewise carry out the disassembly of further segments
Before the disassembly of level 3, remove the stabilizers.
Remove further segments.
Lower the platform until it stops itself.
On the ground level disassemble the diagonal braces of the second segment, then remove
the pins securing connections of the load-bearing structure frames.
Remove the load-bearing structure frames from the second segment.
Disassemble the diagonal and horizontal braces of the first segment that can be found on
the lowest horizontal components.
In order to disassemble the last two side frames of the load-bearing structure, insert the
key in the button located under the platform and press the button.
Photo: 35
Hold down the button until the gears slide out of the gear racks located in the running
profiles.
Pull off the last structure frames from the wheel assembly of the platform.
Disassemble the handrails and toe-boards from the platform.
In order to transport the PRP platform, put the covers on the gears and roller guides.
5.5. Battery Disassembly
Remove the two wing screws located on both sides of the battery box under the platform
to open the battery bay.
Disconnect the connectors between the batteries and the platform.
Remove the batteries from the battery bay and close it back screwing down the bolts.
6. OPERATOR'S MANUAL
The user is responsible for the safety of use of the PRP by establishing safe
working instructions each time
This chapter contains information that is necessary for proper operation of the PRP
manufactured by Lockhard sp. z o. o.
Before attempting to use the PRP, the operator's responsibility is to check that the structure is
complete and correctly assembled.
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You may enter and exit the platform from the ground level only when it is in the lowered
position.
To enter the platform, use only access holes fitted with handrails with access gate.
Before starting work with the PRP, it is necessary to carry out a detailed inspection of the
site in order to identify potential hazards in the work area
While the platform is moving , it is important to stay within the platform
railings and not to protrude beyond their outline.
6.1. Control via control pendant
The control pendant is located on the PRP mobile platform. In order to control the PRP drive
system the following should be done:
Empower the control system - unlock the emergency stop button with the key
Control the platform movement using the UP/DOWN buttons marked with arrows and
colours white / black, respectively
In the event of any emergency, stop the platform movement with the Emergency stop
button - when you press the red button, it cuts off the supply of the control circuit.
6.2. Operator's working station
The working station is on the work platform. While the work platform is moving, do not
protrude beyond its outline.
6.3. Operator's qualifications
In order to ensure proper operation of the PRP, it is important for the operator to have
necessary qualifications to operate Alulift (the required qualifications are subject to legal
regulations applicable in a particular country) and to follow maintenance and inspection
schedule. The operator must have proper qualifications awarded by the Office of
Technical Inspection.
Only trained personnel may be authorized to operate the PRP. Trained personnel are
persons who have the necessary qualifications as specified by legal regulations
applicable in the country where the platform will be used. The operator of Alulift in
Poland must have proper qualifications awarded by the Office of Technical Inspection .
Safe PRP operation requires the operator to understand restrictions, warnings and
operating procedures. The operator must read and understand the complete Operator's
Manual as well as warnings and guidelines contained therein.
The operator must be familiar with the safety regulations.
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6.4. Handling PRP
The PRP can be moved when assembled, sliding is permitted only on vertical, level and
hardened ground of adequate load bearing capacity.
When moving the PRP, it is prohibited to allow persons, materials or tools to remain on
the platform.
The PRP can only be moved by hand and in longitudinal or lateral direction on the
surface free from obstacles
When moving, extreme care and slow pace must be maintained not exceeding pedestrian
pace.
After moving the PRP wheels must be locked by applying stopping brake
Do not move the PRP during wind which could hinder the stability of the device.
After work is complete, PRP type Alulift should be protected against
unauthorised use by third parties by removing the key from the control pendant
and actuating the emergency stop button.
6.5. Troubleshooting
In the event of an emergency situation, in which the working platform will be blocked, e.g. by
using grippers, or in the event of a drive failure (of transmission, drive shaft, rack gear, gear)
do not take any action to restart the platform. How to safely lower the work platform by the
staff remaining on it, should be determined depending on the situation and conditions by
supervisors.
In the case of an emergency, the platform should be removed using a crane or other
equipment.
Instructions for action to be taken by the operator emergency device is triggered.
6.5.1 In the event the emergency brake is activated, the operator should
stop the platform movement using the red emergency button, which cuts-off power
supply from the control circuit,
contact the individuals who are near the PRP and
inform supervisors of the device failure.
6.5.2 Control system failure
Control system failure may include:
battery failure (discharged battery is not a failure, if the batteries are discharged you can
always move downward standing on the platform)
control pendant failure
damaging the control pendant cable
a short circuit in the wiring
switching off a fuse (the most common cause of switching off a fuse is incorrect assembly
of structural frames)
any other situations which make it impossible to restart the platform
In the event that any of the situations specified above occurs, use emergency lowering device to
lower the platform.
6.5.3 Emergency lowering device
Emergency lowering device is a system with an independent power supply system used only to
lower the platform. It is prohibited to use the emergency lowering device in the events of:
mechanical failures
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The emergency lowering device does not switch automatically!!!
To stop the platform release the button of the emergency lowering device one
meter above the surface.
If these instructions are not followed, then this may cause the structure to fall
down and may lead to a serious threat to human health or life.
and to use it at the same time when the main control system is used.
The emergency lowering device is located under the platform. To trigger off the emergency
lowering device remove a rubber cap located on the platform, and then find, press and hold the
button of the emergency lowering device which will cause the platform to move downward. The
button must be held when the platform is moving downward until the working platform is at a
distance of 1 metre from the surface.
After using the emergency lowering device eliminate the reason for failure, after consulting the
technical maintenance team, and then charge the batteries housed in the electric box B by
connecting the plug of the charger to the socket housed in the box.
Photo 36 Photo 37
Photo 38 Photo 39
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Hazards
Residual risk
Crushing hazards due to lack of
space
There is a risk of crushing if the third parties are under the
platform at the time of its downward movement. The risk
arises in the event of a breach of a ban to access under the
platform.
Shearing hazard
Risk of injury when protruding a limb from the work platform
and leaning out during platform vertical movement.
Friction or abrasion hazard
The risk exists when the user of the device is not equipped
with protective clothing.
Failure to use personal
protection equipment
In the case of non-application of personal protective
equipment, personal injury may occur, such as, among others,
abrasions, cuts.
Human errors
Human errors may occur in the event of failure to comply with
instructions for use and installation, which can result in loss of
life or health, damage to the machine and incorrect operation.
Assembly errors
Assembly errors may occur in the event of failure to comply
with instructions for installation, which can result in loss of
life or health, damage to the machine and incorrect operation.
Falling or dropping objects
In the event of working on the platform, the operator is
required to secure materials located on it.
Loss of stability/machine
overturning
In cases of non-compliance with the operation manual of the
device stability may be impaired and the machine may
overturn, which may lead to loss of life, health or damage to
the equipment.
People slipping, tripping or
falling hazards
Slipping hazard may occur in the event of incorrect
maintenance of the work platform, which can cause
contamination on the platform and loss of its non-slip
properties. Tripping hazard may occur in the case of incorrect
material placement on the platform
Inadequate position of controls
In the event of incorrect positioning of the controls, wrong
usage may be caused (swap directions of driving)
Caused by a third party to third
parties
Risk arising out of use or reside on the platform or in its
immediate vicinity unauthorized not and not trained persons.
Exceeded overturning moments
In the event of platform overloading there is a risk of loss of
stability
Secure access to the work
platform
Risk arises as a result of not securing safe access road to the
platform, such as pledging roads through materials that would
restrict access to the platform.
Caused by an abnormal
assembly/use/ maintenance
conditions. Using inadequate
items.
In the event of difficult conditions for assembly, disassembly,
operation and maintenance, human errors may occur, e.g.
wrong installation, poor assessment of components, poor
maintenance, urgency of the works performed
7. HAZARDS IDENTIFICATION AND RESIDUAL RISK INFORMATION
Table 4
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Fault
Presumed cause
Countermeasures
The platform stopping
when it is in motion
Overloaded platform
(switching off fuses)
Checking the platform load, reducing
the platform load
The platform stopping
when it is in motion
Empty batteries
Lowering the platform, replacing or
recharging batteries
The platform stopping
when it is in motion
Incorrect assembly of
vertical structure
Checking correct assembly of vertical
structure
The platform stopping
when it is in motion
No pin bolts
Checking the location of all safety pin
bolts
The platform stopping
when it is in motion
Soiling the gear rack in the
running profile
Visual inspection of the gear rack
cleanness
Countermeasures - cleaning
The platform stopping
when it is in motion
Soiling the running profile
at stabilizer wheels
Visual inspection of the running
profile cleanness
The platform stopping
when it is in motion
Damaging the control
pendant cable, switching on
the emergency button of the
pendant, switching on the
overload protection
Replacing the damaged cable,
unlocking the emergency button
using the key, re-engaging the
overload protection,
IT IS PROHIBITED TO USE ALULIFT IN EXPLOSIVE ATMOSPHERES
Instructions on identifying faults and their location, removing them and re-starting after
intervention operations.
Table 5
8. SAFETY GUIDELINES.
Most accidents are caused by the operator's failure to obey the basic safety rules.
The best guarantee against accidents is a careful
and responsible operator.
Use protective clothing when operating the PRP. Protect your eyes, ears, hands, feet and
body.
Welding works can be performed using the PRP only with special precautions associated
with it.
In case of leaving the PRP unattended, remove the key and lock the emergency stop
button.
Do not wear loose clothing, scarves, jewellery when operating the PRP.
It is prohibited to mount side guards on PRP type Alulift (for example advertising
banners).
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Beware of overhead obstacles or other hazards around the mobile platform when it is in
motion.
Do not lift the mobile platform when the machine is on a truck, forklift truck or any other
device or vehicle. except for special systems from Lockhard Sp. z o.o. which are intended
for this purpose.
Be aware of the danger of crushing. All parts of the body must be kept within the limits of
the mobile platform guardrails when it is in motion.
Do not lower the platform if there are staff, third parties or any other obstacles in the
area below it.
Make sure that there are no staff, third parties or obstacles on the route of the machine.
Take into account any blind spots.
Dangerous driving and fun are strictly prohibited.
Do not modify or alter stops or any other safety devices.
Do not attempt to relieve the wedged platform using controls until the staff exits the
platform.
Before starting work with to operate the PRP, it is necessary to carry out a detailed
inspection of the site in order to identify potential hazards in the work area.
Works on the PRP type Alulift platform are only permitted when using all parts of the
side panel, handrails, knee protection and toe-boards.
It is prohibited to use the PRP platform in the condition indicating the consumption of
alcohol.
It is prohibited to use the control pendant and the emergency lowering device at the
same time.
8.1. Lighting
The PRP is not equipped with its own lighting so the user should provide appropriate
lighting devices on the site.
9. MAINTENANCE INSTRUCTIONS
9.1. Maintenance Operator
Alulift Maintenance Operator is the operator who operates a given device and therefore
such a person must be properly qualified in accordance with current legal provisions in the
country of use. In Poland the operator of Alulift should have proper qualifications to operate
this type of device (hoisting and hauling equipment) awarded by the Office of Technical
Inspection.
9.2. Maintenance and Inspection Schedule
Points which are subject to periodic maintenance or inspection and time periods in which
they should be carried out are given in table 6.
The actual environment of the PRP operation may affect the maintenance schedule.
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Components
Before assembly
(pre-assembly review)
Every 3 months
(maintenance)
Mechanical damage to the structure
1
1
Parking brakes on the wheels
2
2
Wheels
1,2
1,2,4
Running profile 1 1
Handrails/assess handrail
1,2
1,2
Bolts and spacers 3
Drive shaft bearing
4
Diagonal and horizontal braces
1,2
1,2
Gear racks and gears
1
7
Battery chamber locking (bolts)
1,3
1,3
Service brake 2
Electrical wiring
1,8
Limit switches 2 2
Emergency lowering device battery
10
Battery
9
Labels and Manual
1,5,6
1. Visual check
2. Check the operation
3. Check that they are not loose.
4. Lubricate as needed
5. Replace the missing or illegible label or Manual
6. The appropriate Manual should be at the device
7. Check the wear
8. Check the insulation
9. Check the voltage at the battery terminals
10. Check the battery level
Table 6 Time limits for maintenance and inspection
9.3. Pre-assembly reviews
Pre-assembly reviews should be carried out by persons who assemble the PRP. The review
should consist of checking that there was no damage or deformation during transport, in
particular check the components listed in table 2.
9.4. Maintenance Reviews.
Maintenance reviews should be carried out every 90 days (by an authorized operator). The
aim of the review is to check:
The condition of the drive mechanisms, brake systems, load-bearing structure, in
particular welded connections,
The operation of safety components and motion stops,
The maintenance operator (operator) is obliged to:
The operation of the controls and indicators.
record the maintenance review in the PRP maintenance book, stating the date and
sign confirmation of the review results and the operations carried out
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Any noticed defects should be removed immediately after each review before
starting to operate.
Component
Operating Time
Brushes in the motor
1000 operating hours
Gripper
1 year
Transmission
500 operating hours
Gear rack
Allowable wear of 15 %
Gear
Allowable wear of 15 %
Service brake
Replace as required after the service
inspection
immediately notify the PRP's operator of irregularities which caused the necessity of
decommissioning the PRP
9.5. Ad hoc and Service Reviews.
Ad hoc reviews should always be carried out after a break in the PRP operation of longer than 2
weeks (when the device has been assembled but is not used) and after each storm of wind above
6 on the Beaufort scale (i.e. 12 m/s).
The ad hoc review should be carried out by the PRP operator.
An authorized user's employee is responsible for carrying out ad hoc reviews. The results of ad
hoc reviews should be recorded in the PRP maintenance book by the reviewing persons.
The service review is carried out by a service unit authorized by the manufacturer, it is
required every 250 operation hours according to the operating time meter readings or once
a year, whichever comes first.
10. CRITERIA FOR COMPONENTS REPLACEMENT
After the set operating time has elapsed, the following parts should be replaced.
Table 7 Parts to be replaced
11. STORAGE AND TRANSPORT
PRP type Alulift should be stored in enclosed spaces with solid ground. Such storage is best
to protect against rainfall and snow accumulation. Avoid dirt, dust or other contamination.
Batteries should be stored at positive temperature, according to DTR [English: OMD Operation and Maintenance Documentation].
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12. AN INFORMATION BOARD PLACED ON THE PRODUCT
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13. Guarantee and warranty
PRP type Alulift platform is covered by 2-year guarantee if the user logs on the
manufacturer's website and registers in the system, or 1-year guarantee in the absence of
registration in the company system.
"General conditions of sale and delivery in LOCKHARD" shall apply.
Pursuing rights under the guarantee and warranty is excluded in the event of a personal and
material damage, where they are due to the following:
Using PRP type Alulift with mobile work platform contrary to the Operator's Manual.
Incorrect assembly, start-up, use, operation or servicing of PRP type Alulift .
Using PRP type Alulift with defective, unable to work or poorly assembled safety devices.
Failure to comply with the guidelines included in the Operator's Manual regarding PRP
type Alulift transporting, assembly, start-up, operation, servicing, equipping and storage.
Making changes to the structure of PRP type Alulift on your own.
Carrying out repairs of the device by the unauthorised manufacturer's service
technicians.
Damage resulting from weather conditions.
Damage resulting from large external forces.
Carrying out any modifications to the PRP type Alulift
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Warranty Card No.….
Product name: Mobile Access Platform (PRP) type Alulift .
Type:………………………………………………………………………………………………………
Serial No. ………………………………………………………………………………………………..
Date of manufacture:…………………………………………………………………………………………….
Date of sale:………………………………………………………………………………………….
Seller's signature and stamp Manufacturer's stamp
Sample complaint form
Mr……………………………………………………………………………………………….
Address……………………………………………………………………………………………..
Warranty Card No…………………………………………………………………..
Product Type and Serial No. ……………………………………………………………..
Date of purchase………………………………………………………………………………….
Date of start-up …………………………………………………………………………
Brief description of the fault……………………………………………….............
Date and place ………………… Signature ………………
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Appendix No. 1
Tips for reviews
In order to evaluate the device check:
Device completeness
Platform
Vertical frames
Stabilizers
Diagonal braces
Horizontal braces
Handrails and guardrails
Toe-boards
Wheels
Pin bolts
Technical Condition of individual parts - you must pay attention to the following:
Cracks
Crushing
Breaking
Control pendant :
Emergency stop switch
The up-down buttons
Mechanical buttons lock (correctly working lock prevents simultaneous pressing
the up-down buttons)
Limit switches
Drive system with service brake - description of check
Static test:
Apply the safe working load on the platform - 250 kg
Lift the platform up to the height of approx. 1m
measure the distance between the ground and the lower edge of the shorter
platform edge
leave the platform in this position for approx. 15 min
after the required time has lapsed, re-measure the distance - allowable lowering
- 5 mm
Dynamic test: to be carried once a year
Apply the safe working load on the platform - 250 kg
Make the platform move vertically -
correctly working braking system should smoothly stop the motion after
pressing the up - down button. The platform should be stopped within 10 cm.
Gear rack - allowable wear of 15 %
Gear - allowable wear of 15%
Device marking
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Appendix No. 2
OPERATOR'S MANUAL Version 01 2011
TE4-0227 Smart automatic lead-acid battery charger
For 12V and 24V lead-acid batteries
SAVE THESE INSTRUCTIONS FOR FUTURE USE
This manual contains important safety and operating instructions. To reduce the risk of injury,
please read all instructions and follow them with each use of this product.
IMPORTANT SAFETY GUIDELINES.
WARNING - EXPLOSION HAZARD
Do not use this unit for charging dry-cell batteries
that are commonly used with home appliances. These batteries may burst, causing personal
injury and damage to property. Use the unit for charging/boosting a LEAD-ACID battery only.
WARNING - SHOCK HAZARD
Do not use the unit with a damaged cable or plug or if it has received a sharp blow, been
dropped, or been otherwise damaged in any way. Do not disassemble the device.
Incorrect reassembly may present the risk of an electric shock or fire.
NEVER submerge this unit in water; do not expose it to rain, snow or use when wet.
To reduce risk of electric shock, disconnect the unit from any power source before
attempting maintenance or cleaning.
WARNING - RISK OF EXPLOSIVE GASES
Working in the vicinity of a lead acid battery is dangerous. Batteries generate explosive
gases during normal battery operation. For this reason, it is of utmost importance that
prior to each use of the charger you read this manual and strictly follow the instructions.
To reduce the risk of battery explosion, follow these instructions and those published by
the battery manufacturer and manufacturer of any equipment you intend to use in the
vicinity of the battery.
The unit employs parts which may produce arcs or sparks. Therefore, if used in a garage
or enclosed area, the unit MUST be placed not less than 18 inches above the floor.
THIS UNIT IS NOT FOR USE BY CHILDREN AND SHOULD ONLY BE OPERATED BY
ADULTS.
CAUTION -TO REDUCE THE RISK OF INJURY OR PROPERTY DAMAGE:
Pull cord by plug rather than cord when disconnecting the unit from the power source.
NEVER ATTEMPT TO JUMP-START OR CHARGE A FROZEN BATTERY.
When working with lead acid batteries, always make sure immediate assistance is
available in case of accident or emergency.
Always have protective eyewear when using this product: contact with battery acid may
cause blindness and/or severe burns. Be aware of first aid procedures in case of accidental
contact with battery acid.
Have plenty of fresh water and soap nearby in case battery acid contacts skin.
If battery acid contacts skin or clothing, wash immediately with soap and water for at
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least 10 minutes and get medical attention immediately.
Never smoke or allow a spark or flame in vicinity of vehicle battery, engine or battery
charger.
Remove personal metal items such as rings, bracelets, necklaces and watches when
working with a lead acid battery. A lead-acid battery can produce a short-circuit current
high enough to weld a ring or the like to metal, causing a severe burn.
Never allow battery acid to come in contact with this unit.
Do not operate this unit in a closed area or restrict ventilation in any way.
FIRST AID – SKIN:
If battery acid comes in contact with skin, rinse immediately with water, and then wash
thoroughly with soap and water. If redness, pain, or irritation occurs, seek immediate medical
attention.
FIRST AID – EYES:
If battery acid comes in contact with eyes, flush eyes immediately, for at least 15 minutes and
seek immediate medical attention.
FEATURES
Using state of the art technology, the TE4-0226 Battery Charger with 6 steps enables the re-
charging of batteries to almost 100% of their original capacity.
The device may automatically diagnose, recover, charge and maintain batteries for months, it
ensures fully automatic operation from charge to float modes.
Six output options are available enabling battery charge up to 28.8V, 29.4V, 14.4V, 14.7V,
13.6V and enabling 16V float charge.
It features a 9-stage charging strategy, i.e. Pulse Charge, 6A, 4A, 3A, 2.5A, 1.5A, Boost Charge,
Float Charge & Power Supply mode.
The device is supplied with two detachable and interchangeable colour coded lead sets one
with clamps for bench charging and one with eyelet terminals for permanent attachment to
the battery posts to allow quick connection/disconnection through connector.
No risk of overcharging
Electronically secured against a user's faults.
Spark proof
Overheat protection
Full protected against short circuit and wrong connections
Operates as a power generator( 13.6V/5A)
Boosts deeply discharged batteries (4.5V)
OPERATOR'S MANUAL
1. Connecting the terminal rings/clamps directly to the corresponding connectors on the
battery posts.
Remark:
Ensure correct polarity connection before plugging in the AC power.
Position the RED terminal on the positive post connector
Position the BLACK terminal on the negative post connector
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14.4V / 6A
14.7V / 6A
28.8V / 3A
29.4V / 3A
Reverse polarity hook
up
ON
Unsuitable battery cannot be recharged
Flashing for 12V batteries
Flashing for 24V batteries
2. Connect the AC power cord with the AC power outlet.
When the battery is connected to power supply the battery connected LED indicator
will illuminate.
The charger will automatically select the right voltage according to the battery voltage type and
the corresponding LED indicator will turn on.
(Press MODE button to select a charging mode suitable for cold conditions and AGM
batteries)
The Error LED indicator will turn on for incorrect polarity/Faulty.
Rated maximum 6A charging current for 12V batteries;
Rated maximum 3A charging current for 24V batteries;
Charging status LED indicators to display the battery charging level.
3. Disconnect the AC power cord from the AC power outlet when fully charged. Then disconnect
the power cord from the battery.
Remark:
ALWAYS disconnect the power cord from the power outlet before connecting (or disconnecting)
the charger to (or from) the battery.
CHARGING STAGES
1. Diagnosis & Recovery
The unit automatically checks the battery level after connecting, a unique function - the unit
automatically checks the battery level (detects voltage) If a deeply discharged battery's voltage
is over 4.5V ± 0.5V (for 12V battery) or 16V ± 0.25V (for 24V battery), the charger begins
charging with 1.5A low current to recover it, which terminates when voltage reaches to 10.5V
± 0.25V for (12V battery) or 21V ± 0.25V (for 24V battery) at the beginning of the process, the
charger skips low current charging and it switches over to charging mode.
2. Bulk charge stage
80% of energy is returned in this stage of charging. Here charger performs in multi-stages:
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2. For 24V batteries
a) High Rate Charging:
The charger delivers constant current of 3.0 A until the voltage reaches 25.6 V
b) Medium Rate Charging:
The charger delivers constant current of 2.5A until the voltage reaches 28.2 V at which point
the charger switches to absorption phase.
For 12V batteries
a) High Rate Charging:
The charger delivers constant current of 6.0A until the voltage reaches 12.8V
b) Medium Rate Charging:
The charger delivers constant current of 4.0A until the voltage reaches 13.9V, at this level
constant current is 3.0A until the voltage reaches 14.1V.
Finally the charger delivers 2.5A current until the voltage reaches 14.1V, at which point the
charger switches to absorption phase.
Since current is not delivered at highest constant level, the charger will minimize the heating
up of the battery, and hence will eliminate the build up of gases.
This ensures more efficient and safer performances.
3. Absorption charge stage
Use of a constant high current for extended periods of time risks gassing the battery, therefore
a constant low charging current is given at 1.5A to raise voltage from 28.2V to 28.8V (for 24V
battery) and 14.1V to 14.4V (for 12V battery). In this phase complete charging up to almost
100% is achieved. After the battery is completely charged the charger switches over to float
charging.
Float charge stage
As charger continuously monitors the terminal voltage in order to determine if a float charging
should be initiated, if the battery is loaded and/or terminal voltage falls below 25.6V (for 24V
battery) or 12.8V (for 12V battery), the charger starts float charging pulse at constant 1.5A
until voltage reaches to 28.8V (for 24V battery) or 14.4V (for 12V battery). Now float charging
is discontinued. The cycle of trickle charging and float charging is repeated indefinitely to keep
the battery in good condition when it is not in use and enables the charger to be left connected
indefinitely.
5. "Power supply" 13.6V
a) Float charge stage for 12V SLA batteries: This mode is suitable for float charge of 12V
batteries with capacity range from 14-230Ah. The charger delivers a constant voltage of 13.6V.
This is a float charge mode for applications where maximum capacity from the battery is
required, such as golf carts, floor sweepers, etc.
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Input voltage:
200-260VAC, 50Hz
Output voltage:
12V & 24V (auto-select)
Capacity:
>75%
Charging voltage:
28.8V+-0.25V or 29.4V+-0.25V or 14.4V+-0.25V or 13.6V+-0.25V or
16.5V+-0.25V
Charging Current:
6.0A+-10% or 4.0A+-10% or 3.0A+-10% or 2.5A+10% or 1.5A+10%
Back drain current:
<5mA
Ripple:
Max 150mV, 0.3A
Ambient air
temperature:
-20 deg C to +40 deg C/-4 deg F to 104 deg F, Reduced output power at a
higher temperature
Battery TYPES:
12V & 24V lead-acid batteries (WET, MF, AGM and GEL)
Housing protection:
IP65 (Dust and Splash proof)
b) "Power source" mode: TE4-0226 battery charger is also used as a power supply, without
attaching a battery in this mode. The charger delivers 13.6V/4A. Please note that in this mode
spark free function is inactivated. However reverse polarity protection function still works. To
enter the 13.6V supply mode, follow the steps:
a) Disconnect the battery;
b) Connect to the electric power supply;
c) Press and hold the MODE button for 3~5 seconds to active the function;
When this mode is activated, the charger maximum output current will be 13.6Volt / 4Amp.
In this mode, we can use the charger as a Power Supply to provide constant power to 12V DC
appliances with maximum 4A output current.
6. Boost charge 16V/1,5A
This stage is aimed at recovering severely discharged 12V batteries. High voltage (17V max) at
1.5A is applied to a maximum period of 2 hours. At the end of this stage it would switch to a
normal charge procedure (14.4V).
CAUTION: High voltage may cause some water loss, hence this mode should be handled
carefully.
SPECIFICATIONS:
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Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Maintenance booklet
Mobile Access Platform type Alulift
Details of the device:
Type:…………………….……………………………………………………………………
Serial no. .....................................................................................................................
Year of manufacture: .............................................................................................
Load capacity:……………………………………………………………………….........
Dimensions of the platform:………………………………………………………...
Voltage:………………………………………………………………….............................
Engine power: ……………………………………………………………………….......
Details of the owner:
Name:………………………………………………………………………………………...
Address………………………………………………………………………………………
…………………………………………………………………………………………………..
………………………………………………………………………………………………….
Operator (maintenance operator):
.........................................................................................................................................
August 2015 Page 48
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Date
A list of operations
performed
Current
meter
reading
[h]
Technical
condition of
the device
Date of the
next
periodic
inspection
of the unit
Maintenance
operator's
signature and
stamp
Notes
August 2015 Page 49
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Date
A list of operations
performed
Current
meter
reading
[h]
Technical
condition
of the device
Date of the
next
periodic
inspection
of the unit
Maintenance
operator's
signature and
stamp
Notes
August 2015 Page 50
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Date
A list of operations
performed
Current
meter
reading
[h]
Technical
condition of
the device
Date of the
next
periodic
inspection
of the unit
Maintenance
operator's
signature and
stamp
Notes
August 2015 Page 51
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Date
A list of operations
performed
Current
meter
reading
[h]
Technical
condition of
the device
Date of the
next
periodic
inspection
of the unit
Maintenance
operator's
signature and
stamp
Notes
August 2015 Page 52
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Date
A list of operations
performed
Current
meter
reading
[h]
Technical
condition of
the device
Date of the
next
periodic
inspection
of the unit
Maintenance
operator's
signature and
stamp
Notes
August 2015 Page 53
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
Date
A list of operations
performed
Current
meter
reading
[h]
Technical
condition of
the device
Date of the
next
periodic
inspection
of the unit
Maintenance
operator's
signature and
stamp
Notes
August 2015 Page 54
Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
August 2015 Page 55
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